U.S. patent application number 09/955332 was filed with the patent office on 2002-03-21 for containers having spout and process for producing same.
This patent application is currently assigned to SHIKOKU KAKOKI CO., LTD.. Invention is credited to Fujikawa, Yasuji, Iwano, Fumiyuki, Shinohara, Mitsuhiko, Ueda, Michio.
Application Number | 20020033395 09/955332 |
Document ID | / |
Family ID | 18770367 |
Filed Date | 2002-03-21 |
United States Patent
Application |
20020033395 |
Kind Code |
A1 |
Iwano, Fumiyuki ; et
al. |
March 21, 2002 |
Containers having spout and process for producing same
Abstract
A container having a spout of thermoplastic synthetic resin
fixed to an outlet edge portion defining a liquid outlet formed in
a top portion of the container. The outlet edge portion of the
container is covered with a thermoplastic synthetic resin layer at
least over inner and outer surfaces thereof. The spout comprises a
tubular body, and inner and outer two outward flanges formed at one
end of the tubular body integrally therewith and holding the outlet
edge portion of the container therebetween from inside and outside.
The inner and outer flanges of the spout are fixed respectively to
the inner and outer surfaces of the outlet edge portion of the
container.
Inventors: |
Iwano, Fumiyuki; (Tokushima,
JP) ; Fujikawa, Yasuji; (Tokushima, JP) ;
Shinohara, Mitsuhiko; (Tokushima, JP) ; Ueda,
Michio; (Tokushima, JP) |
Correspondence
Address: |
ARMSTRONG,WESTERMAN & HATTORI, LLP
1725 K STREET, NW.
SUITE 1000
WASHINGTON
DC
20006
US
|
Assignee: |
SHIKOKU KAKOKI CO., LTD.
Tokushima
JP
|
Family ID: |
18770367 |
Appl. No.: |
09/955332 |
Filed: |
September 19, 2001 |
Current U.S.
Class: |
220/258.2 ;
220/270; 229/125.05; 229/125.15 |
Current CPC
Class: |
B29C 65/08 20130101;
B29C 66/53247 20130101; B29C 66/61 20130101; B29C 66/73921
20130101; B29C 65/561 20130101; B29C 65/7838 20130101; B29C 66/63
20130101; B29C 65/568 20130101; B29C 66/81431 20130101; B29C
66/12441 20130101; B65D 5/746 20130101; B29C 65/7841 20130101; B29C
65/56 20130101; B29C 66/81423 20130101; B29C 66/12469 20130101;
B29C 66/131 20130101; B29C 66/81425 20130101; B29C 66/81427
20130101; B29L 2031/7166 20130101; B29C 66/83221 20130101; B29C
66/72328 20130101; B29K 2711/123 20130101 |
Class at
Publication: |
220/258 ;
220/270; 229/125.05; 229/125.15 |
International
Class: |
B65D 017/34; B65D
051/20 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 21, 2000 |
JP |
2000-286448 |
Claims
What is claimed is:
1. A container having a spout of thermoplastic synthetic resin
fixed to an outlet edge portion defining a liquid outlet formed in
a top portion of the container, the outlet edge portion of the
container being covered with a thermoplastic synthetic resin layer
at least over inner and outer surfaces thereof, the spout
comprising a tubular body, and inner and outer two outward flanges
formed at one end of the tubular body integrally therewith and
holding the outlet edge portion of the container therebetween from
inside and outside, the inner and outer flanges being fixed
respectively to the inner and outer surfaces of the outlet edge
portion of the container.
2. A container having a spout according to claim 1 wherein the
outer flange is smaller than the inner flange in outside
diameter.
3. A container having a spout according to claim 2 wherein the
outer flange has an upper surface upwardly protuberant in cross
section and bulging upward at a radial midportion thereof.
4. A container having a spout according to claim 1 wherein the
inner flange is smaller than the outer flange in outside
diameter.
5. A container having a spout according to claim 4 wherein the
inner flange has a lower surface downwardly protuberant in cross
section and bulging downward at a radial midportion thereof.
6. A container having a spout according to claim 1 wherein the
inner and outer flanges are equal to each other in outside
diameter.
7. A process for producing a container having a spout according to
claim 1, the process being characterized by preparing a spout blank
of thermoplastic synthetic resin comprising a tubular body, a first
outward flange formed at one end of the blank tubular body
integrally therewith and having an outside diameter larger than the
diameter of the liquid outlet of the container, the first outward
flange being positionable along one of the inner and outer surfaces
of the outlet edge portion, and a flange forming portion provided
on an outer periphery of the blank tubular body integrally
therewith and spaced apart from the first outward flange axially of
the blank tubular body, the flange forming portion being insertable
through the liquid outlet of the container, inserting the blank
tubular body through the liquid outlet of the container to position
the first outward flange along one of the inner and outer surfaces
of the outlet edge portion, clamping the first outward flange thus
positioned, the outlet edge portion of the container and the flange
forming portion between a sealing member and an anvil, joining the
first outward flange to the outlet edge portion of the container by
heat sealing, and forming a second outward flange by melting the
flange forming portion and joining the second outward flange to the
outlet edge portion of the container by heat sealing simultaneously
with the first outward flange.
8. A process for producing a container having a spout according to
claim 7 wherein one of a clamping face of the sealing member and a
clamping face of the anvil to be brought into contact with the
flange forming portion has a flange forming annular groove formed
therein over the entire circumference of the clamping face, and the
second outward flange is formed by filling the groove with molten
synthetic resin provided by the flange forming portion on
melting.
9. A process for producing a container having a spout according to
claim 8 wherein the groove is defined by a side face positioned
radially inwardly of the sealing member or the anvil and in the
form of slope slanting radially outwardly thereof toward a
bottom.
10. A process for producing a container having a spout according to
claim 7 wherein one of a clamping face of the sealing member and a
clamping face of the anvil to be brought into contact with the
flange forming portion is in the form of a stepped face comprising
a radially outward face portion to be brought into contact with one
of the inner and outer surfaces of the outlet edge portion of the
container, and a radially inward face portion cooperative with said
one surface of the outlet edge portion to define a flange forming
clearance therebetween, and the second outward flange is formed by
filling the flange forming clearance between the radially inward
face portion and said one surface of the outlet edge portion with
molten synthetic resin provided by the flange forming portion on
melting.
11. A process for producing a container having a spout according to
any one of claims 7 to 10 wherein the heat sealing is effected by
ultrasonic sealing.
12. A process for producing a container having a spout according to
claim 1, the process being characterized by forming the spout on a
container by injection molding integrally therewith at an outlet
edge portion defining a liquid outlet formed therein, the container
blank being covered with a thermoplastic synthetic resin layer at
least over inner and outer surfaces thereof, the spout comprising a
tubular body projecting outward, and inner and outer two outward
flanges formed at one end of the tubular body integrally therewith
for holding the outlet edge portion of the container therebetween
from inside and outside, and fixedly joining the inner and outer
flanges respectively to the inner and outer surfaces of the outlet
edge portion simultaneously with the formation of the spout.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to containers having a spout
for containing beverages such as fruit juice, milk or sake, and
also to a process for producing the same.
[0002] Such containers having a spout are conventionally produced
in the following manner. Prepared first by injection molding is a
spout of thermoplastic synthetic resin which comprises a tubular
body and an outward flange formed at one end of the tubular body
integrally therewith. The spout is joined to a container covered
with a thermoplastic synthetic resin at least over the inner and
outer surfaces thereof by inserting the tubular body of the spout
through a liquid outlet of the container from inside to position
the outward flange on the inner surface of an outlet edge portion
of the container defining the liquid outlet, then clamping the
container outlet edge portion and the outward flange by an
ultrasonic horn and an anvil, and causing the horn to produce
ultrasonic waves to join the outward flange to the inner surface of
the outlet edge portion by heat sealing.
[0003] In view of work efficiency of the conventional process in
inserting the spout tubular body through the liquid outlet, the
diameter of the liquid outlet is made slightly greater than the
outside diameter of the tubular body, so that the inner periphery
of the edge portion defining the outlet is not joined to the outer
periphery of the tubular body by heat sealing, permitting a small
clearance to remain therebetween. It is therefore impossible to
thoroughly sterilize the portions defining the clearance to result
in a reduced antiseptic effect. Moreover, the presence of the
clearance makes the container appear less aesthetic and less
sanitary.
SUMMARY OF THE INVENTION
[0004] An object of the present invention is to overcome the above
problem and to provide containers having a spout which are improved
in antiseptic effect over conventional ones and appear more
aesthetic and sanitary than conventionally, and a process for
producing such containers.
[0005] The present invention provides a container having a spout of
thermoplastic synthetic resin fixed to an outlet edge portion
defining a liquid outlet formed in a top portion of the container,
the outlet edge portion of the container being covered with a
thermoplastic synthetic resin layer at least over inner and outer
surfaces thereof, the spout comprising a tubular body, and inner
and outer two outward flanges formed at one end of the tubular body
integrally therewith and holding the outlet edge portion of the
container therebetween from inside and outside, the inner and outer
flanges being fixed respectively to the inner and outer surfaces of
the outlet edge portion of the container.
[0006] With the container of the present invention, the spout has
inner and outer two outward flanges formed at one end of its
tubular body integrally therewith and holding the outlet edge
portion of the container therebetween from inside and outside. The
two outward flanges are fixedly joined respectively to the inner
and outer surfaces of the outlet edge portion of the container. It
is therefore unlikely that a clearance visible from outside will be
present in the liquid outlet around the tubular body. This ensures
effective sterilization to achieve an improved antiseptic effect,
making the container appear more aesthetic and sanitary.
[0007] The present invention provides a first process for producing
the container described above and having a spout, the process being
characterized by preparing a spout blank of thermoplastic synthetic
resin comprising a tubular body, a first outward flange formed at
one end of the blank tubular body integrally therewith and having
an outside diameter larger than the diameter of the liquid outlet
of the container, the first outward flange being positionable along
one of the inner and outer surfaces of the outlet edge portion, and
a flange forming portion provided on an outer periphery of the
blank tubular body integrally therewith and spaced apart from the
first outward flange axially of the blank tubular body, the flange
forming portion being insertable through the liquid outlet of the
container, inserting the blank tubular body through the liquid
outlet of the container to position the first outward flange along
one of the inner and outer surfaces of the outlet edge portion,
clamping the first outward flange thus positioned, the outlet edge
portion of the container and the flange forming portion between a
sealing member and an anvil, joining the first outward flange to
the outlet edge portion of the container by heat sealing, and
forming a second outward flange by melting the flange forming
portion and joining the second outward flange to the outlet edge
portion of the container by heat sealing simultaneously with the
first outward flange.
[0008] The present invention provides a second process for
producing the container and described above and having a spout, the
process being characterized by forming the spout on a container by
injection molding integrally therewith at an outlet edge portion
defining a liquid outlet formed therein, the container blank being
covered with a thermoplastic synthetic resin layer at least over
inner and outer surfaces thereof, the spout comprising a tubular
body projecting outward, and inner and outer two outward flanges
formed at one end of the tubular body integrally therewith for
holding the outlet edge portion of the container therebetween from
inside and outside, and fixedly joining the inner and outer flanges
respectively to the inner and outer surfaces of the outlet edge
portion simultaneously with the formation of the spout.
[0009] The spout-equipped container of the invention can be
produced relatively easily by either one of the two processes
described. Especially, the second process is less costly than the
first.
[0010] The present invention will be described in greater detail
with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an enlarged view in section showing a first
embodiment of spout-equipped container of the present
invention;
[0012] FIG. 2 is an enlarged view in section showing a modification
of a tubular body of the first embodiment and that of a cap for
closing an upper-end opening of the tubular body;
[0013] FIG. 3 is a perspective view showing a first embodiment of
process for producing the spout-equipped container of the
invention;
[0014] FIG. 4 includes enlarged views in section showing the first
embodiment of process for producing the spout-equipped container of
the invention;
[0015] FIG. 5 includes enlarged views in section showing a second
embodiment of process for producing a spout-equipped container of
the invention;
[0016] FIG. 6 includes enlarged views in section showing a third
embodiment of process for producing a spout-equipped container of
the invention;
[0017] FIG. 7 includes enlarged views in section showing a fourth
embodiment of process for producing a spout-equipped container of
the invention;
[0018] FIG. 8 is an enlarged view in section showing a second
embodiment of spout-equipped container of the invention;
[0019] FIG. 9 is an enlarged view in section showing a modification
of a tubular body of the second embodiment and that of a cap for
closing an upper-end opening of the tubular body;
[0020] FIG. 10 is a perspective view showing a fifth embodiment of
process for producing the spout-equipped container of the
invention; and
[0021] FIG. 11 is an enlarged view in section showing the fifth
embodiment of process for producing the spout-equipped container of
the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Throughout the drawings, like parts are designated by like
reference numerals and will not be described repeatedly. In the
following description, the upper and lower sides of FIGS. 1, 2 and
4 to 9 will be referred to as "upper" and "lower,"
respectively.
[0023] FIG. 1 shows a first embodiment of spout-equipped container
of the invention.
[0024] With reference to FIG. 1, the container 1 is made from a
paper-base laminate covered with a thermoplastic synthetic resin
layer, e.g., a polyethylene layer 2, over inner and outer opposite
surfaces thereof, and has a spout 4 made of a thermoplastic
synthetic resin, e.g., polyethylene, and fixedly joined to an edge
portion defining a liquid outlet 3 formed in a top portion of the
container 1.
[0025] The spout 4 comprises a tubular body 5 having a closed lower
end and an open upper end, and inner and outer two outward flanges
6, 7 formed at the lower end of the tubular body 5 integrally
therewith and holding the edge portion defining the liquid outlet 3
of the container 1. The flanges 6, 7 are formed respectively on
upper and lower ends of outer periphery of a large-diameter portion
5a integral with the lower end of the tubular body 5. The
large-diameter portion 5a has such an outside diameter that it is
snugly fittable in the liquid outlet 3. The outside diameter of the
large-diameter portion 5a may be smaller than the inside diameter
of the liquid outlet 3 to provide a small clearance in the outlet 3
around the large-diameter portion 5a. The outer flange 7 is
slightly smaller than the inner flange 6 in outside diameter and
has an outer peripheral edge positioned radially inwardly of the
outer peripheral edge of the inner flange 6. The outer flange 7 has
an upper surface upwardly protuberant and bulging upward at a
radial midportion thereof. The inner and outer flanges 6, 7 are
fixedly joined to the respective inner and outer surfaces of the
edge portion defining the outlet 3 of the container 1.
[0026] The tubular body 5 has a wall 5b closing the lower end
thereof and provided with an annular score 8 in its upper surface
along the periphery thereof. The portion of the closing wall 5b
surrounded by the score 8 is integrally provided with an upwardly
projecting knob 9 for separating off this portion.
[0027] The upper-end opening of the tubular body 5 of the spout 4
is closed with a cap 10 removably fittable over the upper end of
the tubular body 5. An annular groove 11 is formed in the outer
periphery of an upper end portion of the tubular body 5 over the
entire circumference thereof. The cap 10 includes a short
cylindrical skirt 12 having such an inside diameter that the skirt
12 is fittable around the upper end portion of the tubular body 5
in intimate contact therewith. The skirt 12 is provided on its
inner periphery with an annular inner protrusion 12a integral
therewith and extending over the entire circumference thereof. The
protrusion 12a fits in the annular groove 11, whereby the cap 10 is
removably held to the upper end portion of the tubular body 5.
[0028] FIG. 2 shows a modification of the tubular body of the first
embodiment and that of the cap for closing the upper-end opening of
the tubular body.
[0029] The modified tubular body 5 has an externally threaded
portion 15 on its outer periphery. A cap 16 includes a skirt 17
having a shorter length than the tubular body 5 and provided with
an internally threaded portion 18 on its inner periphery. Using the
externally and internally threaded portions 15, 18, the cap 16 is
screwed on the tubular body 5 and thereby removably attached to the
body 5. FIGS. 3 and 4 show a first embodiment of process for
producing the spout-equipped container of the invention, i.e., the
spout-equipped container 1 shown in FIG. 1.
[0030] First, a spout blank 20 of approximately the same shape as
the spout 4 is made from polyethylene by injection molding before
practicing the process. The blank 20 differs from the spout 4 in
that a large-diameter portion 25 of tubular body 5 of the blank 20
at its lower end has an outside diameter which is slightly smaller
than the inside diameter of the liquid outlet 3, and that in place
of the outer flange 7 of the spout 4, an upwardly projecting
annular flange forming portion 21 is formed along the outer
periphery of upper end of the large-diameter portion 25 integrally
therewith over the entire circumference [see FIG. 4(a)].
[0031] The portion of tubular body 5 of the spout blank 20 above
the inner outward flange 6 thereof is then inserted through the
liquid outlet 3 formed in the top portion of a container 1 from
inside the container 1 to position the inner flange 6 beneath the
inner surface of the edge portion defining the outlet 3. The flange
forming portion 21, the outlet-defining edge portion of the
container 1 and the inner flange 6 in this state are clamped
between an annular clamping face 22a of a horn 22 (sealing member)
of an ultrasonic sealing device disposed outside the container 1
and an annular clamping face 23a of an anvil 23 disposed inside the
container 1. The clamping face 22a of the horn 22 and the clamping
face 23a of the anvil 23 are equal in width. The width of the anvil
clamping face 23a is equal to the distance from the outer periphery
of the inner flange 6 to a radial intermediate portion of the
large-diameter portion 25. A V-shaped flange forming annular groove
24 24 is formed in the clamping face 22a of the horn 22 over the
entire circumference thereof. The groove 24 is defined by a side
face positioned radially inwardly of the horn 22 and slanting
radially outwardly thereof toward a bottom, and a side face
positioned radially outwardly of the horn and slanting radially
inwardly thereof toward the bottom. The slope of the radially
inward side face with respect to the clamping face 22a is smaller
than the slope of the radially outward side face with respect to
the clamping face 22a. The portion of the horn clamping face 22a
positioned radially outwardly of the groove 24 is brought into
contact with the outer surface of the outlet-defining edge portion
of the container 1, while the clamping face portion positioned
radially inwardly of the groove is brought into contact with the
upper end face of the large-diameter portion 25 positioned radially
inwardly of the flange forming portion 21 [see FIG. 4(a)].
[0032] Ultrasonic waves are then produced from the horn 22, whereby
the inner outward flange 6 is joined to the inner surface of the
edge portion defining the outlet 3 by heat sealing. At the same
time, an outer outward flange 7 is formed by molten synthetic resin
provided by the flange forming portion 21 on melting and filling
the groove 24, and is joined to the outer surface of the
outlet-defining edge portion of the container 1 by heat sealing.
The molten resin afforded by the flange forming portion 21 further
fills up a clearance in the liquid outlet 3 around the
large-diameter portion 25 to form a large-diameter portion 5a [see
FIG. 4(b)]. In this way, the spout-equipped container is
produced.
[0033] FIG. 5 shows a second embodiment of process for producing a
spout-equipped container of the present invention.
[0034] As shown in FIG. 5(a), a spout blank 30 of approximately the
same shape as the spout 4 shown in FIG. 1 is first made from
polyethylene by injection molding before practicing the process.
The blank 30 differs from the spout blank 20 shown in FIG. 4 in
that in place of the annular flange forming portion 21, a flange
forming portion 31 integral with the upper end of the
large-diameter portion 25 and equal to this portion 25 in outside
diameter is formed integrally with the portion 25 and the tubular
body 5. The flange forming portion 31 has an upper end face
slanting downward radially outwardly of the body 5.
[0035] The portion of tubular body 5 of the spout blank 30 above
the inner outward flange 6 thereof is then inserted through the
liquid outlet 3 formed in the top portion of a container 1 from
inside the container 1 to position the inner flange 6 beneath the
inner surface of the edge portion defining the outlet 3. The flange
forming portion 31, the outlet-defining edge portion of the
container 1 and the inner flange 6 in this state are clamped
between an annular clamping face 22a of horn 22 (sealing member) of
an ultrasonic sealing device disposed outside the container 1 and
an annular clamping face 23a of an anvil 23 disposed inside the
container 1. The clamping face 22a of the horn 22 comprises a
radially outward face portion 32 to be brought into contact with
the outer surface of the edge portion defining the liquid outlet 3
of the container 1, and a radially inward face portion 33 slightly
recessed upward from the face portion 32 and cooperative with the
outer surface of the outlet-defining edge portion to define a
flange forming clearance therebetween [see FIG. 5(a)].
[0036] Ultrasonic waves are then produced from the horn 22, whereby
the inner outward flange 6 is joined to the inner surface of the
edge portion defining the outlet 3 by heat sealing. At the same
time, an outer outward flange 34 is formed by molten synthetic
resin provided by the flange forming portion 31 on melting and
filling the clearance between the radially inward face portion 33
and the outer surface of the edge portion defining the outlet 3 of
the container 1, and is joined to the outer surface of the
outlet-defining edge portion of the container 1 by heat sealing.
The molten resin afforded by the flange forming portion 31 further
fills up a clearance in the liquid outlet 3 around the
large-diameter portion 25 to form a large-diameter portion 5a [see
FIG. 5(b)]. In this way, the spout-equipped container is
produced.
[0037] With the spout-equipped container thus produced, the outer
outward flange 34 of the resulting spout 35 is smaller than the
inner outward flange 6 in outside diameter and has an outer
peripheral edge which is positioned radially inwardly of the
corresponding edge of the inner flange 6.
[0038] FIG. 6 shows a third embodiment of process for producing a
spout-equipped container of the present invention.
[0039] As shown in FIG. 6(a), a spout blank 40 of approximately the
same shape as the spout 4 shown in FIG. 1 is first made from
polyethylene by injection molding before practicing the process.
The blank 40 differs from the spout blank 20 shown in FIG. 4(a) in
that the flange forming portion 21 is replaced by an outer outward
flange 43 formed on the outer peripheral upper end of the
large-diameter portion 25, and that in place of the inner outward
flange 6, a downwardly projecting annular flange forming portion 41
is formed along the outer periphery of lower end of the
large-diameter portion 25 integrally therewith over the entire
circumference.
[0040] The portion of tubular body 5 of the spout blank 40 below
the outer outward flange 43 thereof is then inserted through the
liquid outlet 3 formed in the top portion of a container 1 from
outside the container 1 to position the outer flange 43 along the
outer surface of the edge portion defining the outlet 3. The outer
flange 43, the outlet-defining edge portion of the container 1 and
the flange forming portion 41 in this state are clamped between an
annular clamping face 22a of horn 22 (sealing member) of an
ultrasonic sealing device disposed outside the container 1 and an
annular clamping face 23a of an anvil 23 disposed inside the
container 1. The annular clamping face 22a of the horn 22 is flat.
A V-shaped flange forming annular groove 42 is formed in the
clamping face 23a of the anvil 23 over the entire circumerence
thereof. The groove 42 is defined by a side face positioned
radially inwardly of the anvil 23 and slanting radially outwardly
thereof toward a bottom, and a side face positioned radially
outwardly of the anvil and slanting radially inwardly thereof
toward the bottom. The slope of the radially inward side face with
respect to the clamping face 23a is smaller than the slope of the
radially outward side face with respect to the clamping face 23a.
The portion of the anvil clamping face 23a positioned radially
outwardly of the groove 42 is brought into contact with the inner
surface of the outlet-defining edge portion of the container 1,
while the clamping face portion positioned radially inwardly of the
groove is brought into contact with the lower end face of the
large-diameter portion 25 positioned radially inwardly of the
flange forming portion 41 [see FIG. 6(a)].
[0041] Ultrasonic waves are then produced from the horn 22, whereby
the outer outward flange 43 is joined to the outer surface of the
edge portion defining the outlet 3 by heat sealing. At the same
time, an inner outward flange 46 is formed by molten synthetic
resin provided by the flange forming portion 41 on melting and
filling the groove 42, and is joined to the inner surface of the
outlet-defining edge portion of the container 1 by heat sealing.
The molten resin afforded by the flange forming portion 41 further
fills up a clearance in the liquid outlet 3 around the
large-diameter portion 25 to form a large-diameter portion 5a [see
FIG. 6(b)]. In this way, the spout-equipped container is
produced.
[0042] With the spout-equipped container thus produced, the inner
outward flange 46 of the resulting spout 45 is smaller than the
outer outward flange 43 in outside diameter and has an outer
peripheral edge which is positioned radially inwardly of the
corresponding edge of the outer flange 43. The inner flange 46 has
a lower surface downwardly protuberant and bulging downward at a
radial midportion thereof.
[0043] FIG. 7 shows a fourth embodiment of process for producing a
spout-equipped container of the present invention.
[0044] As shown in FIG. 7(a), a spout blank 50 of approximately the
same shape as the spout 4 shown in FIG. 1 is first made from
polyethylene by injection molding before practicing the process.
The blank 50 differs from the spout blank 40 shown in FIG. 6(a) in
that in place of the annular flange forming portion 41, a flange
forming portion 51 extending downward from the large-diameter
portion 25 and equal to this portion 25 in outside diameter is
formed integrally with the portion 25 and the tubular body 5 by
increasing the vertical length of the tubular body 5 and the
large-diameter portion 25. The flange forming portion 51 has a
lower end face slanting upward radially outwardly of the body
5.
[0045] The portion of tubular body 5 of the spout blank 50 below
the outer outward flange 43 thereof is then inserted through the
liquid outlet 3 formed in the top portion of a container 1 from
outside the container 1 to position the outer flange 43 along the
outer surface of the edge portion defining the outlet 3. The outer
outward flange 43, the outlet-defining edge portion of the
container 1 and the flange forming portion 51 in this state are
clamped between an annular clamping face 22a of horn 22 (sealing
member) of an ultrasonic sealing device disposed outside the
container 1 and an annular clamping face 23a of an anvil 23
disposed inside the container 1. The clamping face 22a of the horn
22 is flat. The clamping face 23a of the anvil 23 comprises a
radially outward face portion 44 to be brought into contact with
the inner surface of the edge portion defining the liquid outlet 3
of the container 1, and a radially inward face portion 47 slightly
recessed downward from the face portion 44 and cooperative with the
inner surface of the outlet-defining edge portion to define a
flange forming clearance therebetween.
[0046] Ultrasonic waves are then produced from the horn 22, whereby
the outer outward flange 43 is joined to the outer surface of the
edge portion defining the outlet 3 by heat sealing. At the same
time, an inner outward flange 48 is formed by molten synthetic
resin provided by the flange forming portion 51 on melting and
filling the clearance between the radially inward face portion 47
and the inner surface of the edge portion defining the outlet 3 of
the container 1, and is joined to the inner surface of the
outlet-defining edge portion of the container 1 by heat sealing.
The molten resin afforded by the flange forming portion 51 further
fills up a clearance in the liquid outlet 3 around the
large-diameter portion 25 to form a large-diameter portion 5a [see
FIG. 7(b)]. In this way, the spout-equipped container is
produced.
[0047] With the spout-equipped container thus produced, the inner
outward flange 48 of the resulting spout 55 is smaller than the
outer outward flange 43 in outside diameter and has an outer
peripheral edge which is positioned radially inwardly of the
corresponding edge of the outer flange 43.
[0048] According to the first to fourth embodiments of process for
producing spout-equipped containers of the invention, the flange
forming portion 21, 31, 41 or 51 serves as a guide for inserting
the tubular body 5 of the spout blank 20, 30, 40 or 50 through the
liquid outlet 3 of the container 1. Further with the first to
fourth embodiments, the molten resin provided by the flange forming
portions 21, 31, 41 or 51 on melting need not always fill up the
clearance in the liquid outlet 3 around the large-diameter portion,
but a small clearance may remain in the outlet 3 around the
large-diameter portion 5a of the spout 4, 35, 45 or 55 obtained on
the container 1 produced.
[0049] Further in the case where the molten resin afforded by the
flange forming portion 21, 31, 41 or 51 on melting fills up the
clearance in the outlet 3 around the large-diameter portion 25 to
form a large-diameter portion 5a according to the first to fourth
embodiments of process for producing spout-equipped containers of
the invention, the flange forming portion 21, 31, 41 or 51 need not
always be made into the outward flange 7, 34, 46 or 48, insofar as
the large-diameter portion 5a is joined by heat sealing to the
portion of the polyethylene layer 2 exposed at the inner periphery
defining the liquid outlet 3 which layer 2 is positioned on
opposite side to the position where the outward flange 6 or 43 is
originally provided.
[0050] FIG. 8 shows a second embodiment of spout-equipped container
of the invention.
[0051] FIG. 8 shows a spout 60 which differs from the spout 4 shown
in FIG. 1 in that inner and outer flanges 61, 62 are formed
directly on a tubular body 5 integrally therewith without providing
an intervening large-diameter portion, and that the inner and outer
flanges 61, 62 are equal to each other in outside diameter and
symmetrical in section about a horizontal line positioned
therebetween. The spout 60 is otherwise identical with the spout 4
of FIG. 1.
[0052] FIG. 9 shows a modification of the tubular body 5 of the
second embodiment and that of the cap thereof for closing the
upper-end opening of the tubular body.
[0053] As is the case with the modifications shown in FIG. 2, an
externally threaded portion 15 formed on the outer periphery of the
tubular body 5 and an internally threaded portion 18 formed on the
inner periphery of a skirt 17 are used for screwing the cap 16 on
the tubular body 5, whereby the cap 16 is removably attached to the
tubular body 5.
[0054] FIGS. 10 and 11 show a fifth embodiment of process for
producing the spout-equipped container of the invention shown in
FIG. 9.
[0055] With reference to FIGS. 10 and 11, an injection molding mold
70 having a cavity 71 which is shaped in conformity with the shape
of the spout 60 is disposed for the edge portion of a container 1
defining a liquid outlet 3 thereof. The mold 70 comprises an inner
mold segment 72 disposed inside the container 1, and an outer mold
segment 73 disposed outside thereof. A molten thermoplastic resin,
such as molten polyethylene, is injected into the mold 70 from the
nozzle of an injector via a sprue, runner and gate (not shown),
whereby a spout 60 is molded integrally which comprises an
outwardly projecting tubular body 5, and inner and outer two
outward flanges 61, 62 formed at one end of the tubular body 5
integrally therewith for holding the outlet-defining edge portion
of the container 1 therebetween from inside and outside, with the
inner and outer flanges 61, 62 fixedly joined respectively to the
inner and outer surfaces of the edge portion defining the liquid
outlet 3. In this way, the spout-equipped container is
produced.
[0056] The spout-equipped container shown in FIG. 8 is produced
also in the same manner as above.
[0057] In producing spout-equipped containers by the processes
described above, the bottom of the container 1 is formed before the
spout is fixedly provided in place, or is formed alternatively
after the spout is fixedly provided.
* * * * *